Carbon fiber tubular pole and method of manufacture

ABSTRACT

A carbon fiber tubular pole and method of construction thereof. The pole includes a left in place lightweight mandrel, preferably formed of tubular polyvinylchloride or cardboard, which substantially reduces cost of manufacture. A socket is formed in the carbon fiber tubular pole for receiving an adjacent carbon fiber tubular pole.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates generally to the construction and manufacture oftubular pole members having a distinctive appearance of black carbonfiber, and more particularly to such a pole or contoured support memberand method of forming same at a substantially reduced cost ofmanufacture.

Description of the Related Art

Tubular poles and structural contoured members formed of sleeve carbonfiber are well known. The enhanced strength and overall appearance ofthe black carbon fiber material greatly enhances the strength andaesthetic value despite the greatly exaggerated cost of manufacturingsuch a product in lieu of similar conventional tubular aluminum product.However, the well-known method for manufacturing such a carbon fiberpole which may typically only be made in a shorter, straightconfiguration in the carbon fiber industry is through the use ofhigh-tech procedures such as autoclaving and microfilament machineswhich enable the removal of a mandrel prior to the complete curing ofresin saturated into the carbon fiber material. Moreover, whenmanufacturing smaller diameter carbon fiber tubular members having adiameter of less than 1″, removal of the support mandrel becomesexceedingly difficult.

Further, because the cured carbon fiber tubular structure cannot beformed to produce a curve such as for a bow support for a bimini top ofa boat, there are no such carbon fiber products in the marketplace atthis time.

The present invention provides both a structure and a method forproducing both straight tubular and curved tubular support membersformed of carbon fiber to provide the strength and distinctiveappearance of the black sleeve while substantially reducing the cost ofmanufacture by simply leaving a sacrificial tubular mandrel in placewithin the end product structure. A mandrel is any tube made of asynthetic or fibrous material that has the properties of being round,hollow and lightweight. Examples of a synthetic pole may be PVC tubing,plastic tubing or fiberglass tubing. Such a mandrel is preferably in theform of either a light-weight tubular polyvinylchloride (PVC) tubing orcardboard tubing which are left in place and cured and become amonolithic part of the entire structure.

The foregoing has outlined some of the more pertinent objects of thepresent invention. These objects should be construed as being merelyillustrative of some of the more prominent features and applications ofthe invention. Many other beneficial results can be obtained bymodifying the invention within the scope of the invention. Accordinglyother objects in a full understanding of the invention may be had byreferring to the summary of the invention, the detailed descriptiondescribing the preferred embodiment in addition to the scope of theinvention defined by the claims taken in conjunction with theaccompanying drawings.

SUMMARY OF THE INVENTION

The present invention is defined by the appended claims with specificembodiments being shown in the attached drawings. For the purpose ofsummarizing the invention, the invention relates to an improved carbonfiber tubular pole and curved tubular structural member and method ofconstruction thereof. The end product includes a left in-placelightweight mandrel, preferably formed of tubular synthetic or fibrous,which substantially reduces cost of manufacture. Moreover, an outertubular layer of glass fiber over a tubular carbon fiber layer and curedresin saturated through and through fiber layers maintains the aestheticappearance of the black carbon fiber while substantially strengtheningthe end product.

The method is also incorporated into the forming of a socket in one endof the carbon fiber tubular pole for receiving a end of an adjacentfiber tubular pole.

It is therefore an object of this invention to provide carbon fibertubular poles and curved support members which have the outwardaesthetic appearance of flat black carbon fiber sleeve.

Still another object of this invention is to provide a carbon fibertubular structure formed leaving an inner tubular mandrel in placewithin the structure as a manufacturing support to substantially reducemanufacturing costs.

Yet another object of this invention is to provide a carbon fibertubular structure which is formed over a precontoured or curved tubularmandrel so as to overcome the limitation that tubular carbon fiber polescurrently prohibit the contouring of cured carbon fiber pole stock afterthe resin has been hardened and cured.

Yet another object of this invention is to provide a method of formingtubular carbon fiber members utilizing slow rotation of the member asthe resin is applied to fully saturate the carbon fiber and glass fiberlayers all of the way to the tubular mandrel which insures amonolithic-like structure when cured.

The following embodiments and aspects thereof are described andillustrated in conjunction with systems, tools and methods which aremeant to be exemplary and illustrative and not limiting in scope. Invarious embodiments one or more of the abovedescribed problems have beenreduced or eliminated while other embodiments are directed to otherimprovements. In addition to the exemplary aspects and embodimentsdescribed above, further aspects and embodiments will become apparent byreference to the drawings and by study of the following descriptions.

The foregoing has outlined rather broadly the more pertinent andimportant features of the present invention in order that the detaileddescription that follows may be better understood so that the presentcontribution to the art can be more fully appreciated. Additionalfeatures of the invention will be described hereinafter which form thesubject of the claims of the invention. It should be appreciated bythose skilled in the art that the conception and the specificembodiments disclosed may be readily utilized as a basis for modifyingor designing other structures for carrying out the same purposes of thepresent invention. It should also be realized by those skilled in theart that such equivalent constructions do not depart from the spirit andscope of the invention as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and objects of the invention,reference should be made to the following detailed description taken inconnection with the accompanying drawings in which:

FIG. 1 is a side perspective of one end product produced by themethodology of the disclosure.

FIG. 2 is a side perspective view of another end product produced by themethodology of the disclosure.

FIG. 3 represents a first step in the manufacture of a pole by theteaching of this disclosure.

FIGS. 3 to 15 are side perspective views showing the preferred steps inimplementing the method of this disclosure to produce one embodiment ofan end pole product of this disclosure.

FIG. 16 is a side perspective view showing inserting an alternatesupport tube within the tubular mandrel for temporarily supportinglarger diameter poles during manufacture.

FIG. 17 shows an optional step in the resin curing process for thetubular pole produced in FIG. 16 within the scope of this disclosure.

FIGS. 18 and 19 show an optional and preferred step of applying aresin/silica coating over the cured resin (FIG. 18) and hanging the endproduct vertically for curing.

FIG. 20 is a perspective view of a finished tubular carbon fiber pole.

FIG. 21 is a section view in the direction of arrows 21-21 in FIG. 20.FIG. 21A is an enlarged view of a segment of pole section in FIG. 21.

FIG. 22 shows three perspective views of two alternate embodiments of abimini top support bow or member as well as an exploded view of thesecond embodiment thereof.

FIGS. 23 to 30 are side perspective views showing steps in implementingan alternate method of this disclosure to produce a socket in an endpole product of this disclosure.

FIG. 31 is an assembled view of a first pole section of FIGS. 3 to 15inserted into the socket of a second pole section of FIGS. 23 to 30.

FIG. 32 is a sectional view along line 32-32 in FIG. 31.

FIG. 33 is a view of the first and second pole sections of FIG. 30 in afolded position.

Exemplary embodiments are illustrated in reference figures of thedrawings. It is intended that the embodiments and figures disclosedherein are to be considered to be illustrative rather than limiting.Similar reference characters refer to similar parts throughout theseveral Figures of the drawings.

DETAILED DISCUSSION

The following nomenclature is used throughout the specification anddrawings.

-   10. boat pole assembly-   12. pole assembly-   14. pole-   16. boat hook-   18. finishing end cap-   20. bimini brace assembly-   22. brace assembly-   24. brace-   26. end pivot fitting-   28. mid-pivot bracket-   30. PVC mandrel-   32. support rod-   34. mandrel outer surface-   36. driving notch-   38. carbon fiber sleeve-   40. glass fiber sleeve-   42. uncured resin-   42′. cured resin-   44. uncured resin/silica-   44′. cured resin/silica-   46. pole assembly-   48. large pole-   50. PVC mandrel-   52. carbon fiber sleeve-   54. glass fiber mat-   56. cured resin-   58. cured resin/silica-   60. PVC bimini mandrel-   62. bow segment-   64. corner segment-   66. upright leg-   70. segmented PVC bimini mandrel-   72. bow segment-   74. upright leg-   76. corner segment-   78. connector tube-   80 socket-   90 bell mandrel-   91 narrow cylindrical portion-   92 tapered portion-   93 enlarged cylindrical portion-   101 first pole section-   101 second pole section-   110 end unit-   111 end unit-   112 washer stop-   114 recess-   120 elastic cord-   122 canvas snap

Referring now to the drawings, and firstly to FIGS. 1 and 2, twofinished products produced by the methodology of the present disclosureare there shown generally at numerals 10 and 20. In FIG. 1, the boatpole assembly 10 is formed of an elongated pole assembly 12 whichincludes a tubular carbon fiber pole 14 having a finishing end cap 18which lockingly receives a boat hook 16 held therewithin, the shaft ofwhich extends partway into the tubular pole 14. The finished appearanceshown as being transparent is that of a longitudinally stranded carbonfiber linear sleeve therebeneath. In FIG. 2, a bimini brace is shown at20 and also includes an elongated carbon fiber brace assembly 22 formedof an elongated tubular carbon fiber 6 pole 24. The bimini brace 20,being shown as a product example, also includes an end fitting 26 and amid-span pivot bracket 28 lockingly positioned and functioning in aconventional manner.

Referring now to FIGS. 3 to 15, the methodology of this disclosureproducing the product shown typically shown in FIGS. 1 and 2, is thereshown. In FIG. 3, an elongated removable support rod 32, preferablyformed of aluminum or copper, is inserted into a length ofpolyvinylchloride (PVC) mandrel 30, the PVC mandrel 30 forming apermanent part of each end product. The support rod 32 is slid into thehollow interior of the mandrel 30 in the direction of arrow A.Thereafter, the outer surface 34 of the mandrel 30, supported by thesupport rod 32, is sanded and roughened so as to better adhere to resinapplied thereover in a later step.

As seen in FIG. 5, driving notches 36 are formed into one end of themandrel 30 after which a plug guide is slid part way into that same endof the mandrel 30 in the direction of arrow B. The rounded distal end ofthe plug guide is left exposed so that, as seen in FIG. 7, a length oftubular carbon fiber sleeve 38 may be easily slidingly engaged onto theouter surface of the mandrel 30 in the direction of arrow C. Once thiscarbon fiber sleeve 38 is fully in place over the mandrel 30 as shown inFIG. 8, the carbon fiber sleeve 38 is manually stretched as arrow D inthe direction of arrows E in FIG. 9 so as to more tightly conformagainst the exterior surface of the mandrel 30. Thereafter, as seen inFIG. 10, a length of tubular glass fiber sleeve 40 is slid over the topof the carbon fiber sleeve 38 in the direction of arrow F. Once theglass fiber sleeve 40 is in position over the previously stretched andtensioned carbon fiber sleeve 38, the glass fiber sleeve 40 is alsostretched in the direction of arrows G and tensioned in the direction ofarrows H by manual manipulation thereof to insure outstretched andtightened position of the glass fiber sleeve 40. This manipulation issimilar to the collapsing and tightening of “Chinese handcuffs”.

The preferred carbon fiber sleeve is formed of either tubular biaxial orunidirectional carbon fiber material. The preferred glass fiber sleeveis roving biaxial sleeving.

This entire arrangement shown in FIG. 12 is then positioned onto arotary apparatus by sliding the driving notch 36 into engagement ondriving pin of the drive shaft of the rotary, after which the supportshaft is moved into the opposite end of the mandrel 30 in the directionof arrow J.

The rotary is then activated to slowly (about 1 to 5 RPM) rotate themandrel 30 in the direction of arrow L simultaneously with brushapplication of uncured resin 42 applied over all of the exterior surfaceof the glass fiber sleeve 40. The resin 42 may be vinyl or polyesterepoxy and of sufficiently low viscosity so as to fully penetrate throughboth the glass fiber sleeve 40 and the carbon fiber sleeve 38 to fullysaturate those layers down to the outer surface of the mandrel 30. Asseen in FIG. 15, thereafter a user wearing protective vinyl or latexgloves then smoothes the entire arrangement of resin 42, glass fiber andcarbon fiber sleeves 38 and 40 by movement manually in the direction ofarrows M while squeezing. The preferred resin is a low viscosity epoxyusing a non-flushing hardener, slow, medium, or fast curing dependingupon ambient temperature.

For smaller diameter products, curing of the resin may take place whilebeing held with or without rotation within the rotary shown in FIG. 15.However, where the diameter of the end product exceeds about 1″, it ispreferred that a support tube be inserted into the mandrel 30 as shownin FIG. 16. The mandrel 30, being non-porous with respect to uncuredresin 42, will prevent any resin 42 from contacting the outer surface ofthe support tube, eliminating any risk that the support tube may not beeasily removed after the resin 42 applied to the outer surface shown inFIGS. 14 and 15 has cured.

Once this support tube is inserted in the direction of arrow N as seenin FIG. 16, the ends of the support tube may be held horizontally or, asseen in FIG. 17, for larger diameter end product, the support tube maybe attached to and hung vertically by a hanger at an upper end and, toprevent the mandrel 30 from sliding downwardly, a stop pin may beinserted through the opposite end of the support tube. The work productis being held vertically so as to insure a perfectly straight pole endproduct and without the risk of the resin running which is insured bythe careful, even distribution of all uncured resin in the step shown inFIG. 15.

In FIG. 18, after the resin 42 has been cured and hardened, it ispreferred that an outer layer of resin in combination with a smallquantity of colloidal silica at 44 be brush applied while rotating thework product. Alternately, the entire arrangement is then removed fromthe rotary into an upright orientation shown in FIG. 19 wherein thehanger is attached to an overhead support after a stop pin has beenpositioned through.

a transverse aperture through the support tube at the opposite endthereof. The colloidal silica/resin outer coat 44′ provides a moreserviceable and smoother surface.

Referring now to FIGS. 20, 21 and 21A, a segment of a length of carbonfiber pole is there shown at 46. Again, the finished carbon fiber 48 hasa translucent or transparent visual effect through the cured resin 56and the outer glass fiber sleeve 54 so that the black carbon fibersleeve 52 is visible through these combined layers of resin and glassfiber sleeve. As seen in FIG. 21B, the preferred embodiment alsoincludes the outer layer of cured resin with colloidal silica 58 whichis applied manually over the cured surface of the resin 56 as previouslydescribed.

Referring now to FIG. 22, the tubular mandrel aspect of the presentinvention

is applied to curved tubular structural members such as the support bowof a bimini top of a sailboat or power boat. In one embodiment 60, thePVC mandrel 62 is heated and formed at 64 so as to provide straightupright legs 66 and a large radius curved center portion 62 configuredas aesthetically dictated for the bimini canvas. Alternately, the PVCmandrel may be formed in segmented portions at 70 wherein the centerportion 72 is first heated and formed around a suitable form or manuallyand then interconnected to tightly bent corners 76 by connectors 78 forattachment to elongated upright tubular portions 74 to form the samedesired configuration as with respect to the mandrel 60.

It is again stressed that the important aspect of this invention is thatthe inner mandrel becomes a permanent part of each hollow carbon fiberpole or contoured product. The resin is saturated through the outerlayer of glass fiber and through the inner layer of carbon fiber sleeveto reach and become a monolithic part with the inner tubular mandrelwhich again may be formed of polyvinylchloride material, cardboardmaterial or any other suitable material which affords a lightweighttubular inner form over which the carbon fiber sleeve, the glass fibersleeve, and the resin are applied. While a number of exemplary aspectsand embodiments have been discussed above, those of skill in the artwill recognize certain modifications, permutations and additions andsubcombinations thereof. It is therefore intended that the followingappended claims and claims hereinafter introduced are interpreted toinclude all such modifications, permutations, additions andsubcombinations that are within their true spirit and scope.

FIGS. 23 to 30 are side perspective views showing steps in implementingan alternate method of this disclosure to produce a socket 80 in an endpole product of this disclosure.

FIG. 23 illustrates a plug guide being slid part way into one end of themandrel 30 in the direction of arrow B. A bell mandrel 90 has a narrowcylindrical portion 91, an enlarged cylindrical portion 92 and anintermediated tapered portion 93. The narrow cylindrical portion 91 isinserted into the other end of the mandrel 30

FIG. 24 illustrates a length of tubular carbon fiber sleeve 38 beingslidingly engaged onto the outer surface of the mandrel 30 in thedirection of arrow C.

FIG. 25 illustrates the carbon fiber sleeve 38 is fully in place overthe mandrel 30 and the intermediated tapered portion 93 and the enlargedcylindrical portion 92 of the bell mandrel 90.

FIG. 26 illustrates the carbon fiber sleeve 38 being manually stretchedas arrow D in the direction of arrows E so as to more tightly conformagainst the exterior surface of the mandrel 30 and the intermediatedtapered portion 93 and the enlarged cylindrical portion 92 of the bellmandrel 90.

FIG. 27 illustrates a length of tubular glass or carbon fiber sleeve 40is slid over the top of the carbon fiber sleeve 38 in the direction ofarrow F.

FIG. 28 illustrates the length of tubular glass or carbon fiber sleeve40 positioned over the previously stretched and tensioned carbon fibersleeve 38 overlaying the intermediated tapered portion 93 and theenlarged cylindrical portion 92 of the bell mandrel 90.

FIG. 29 illustrates the glass or carbon fiber sleeve 40 being stretchedin the direction of arrows G and tensioned in the direction of arrows Hby manual manipulation thereof to insure outstretched and tightenedposition of the glass fiber sleeve 40.

FIG. 30 illustrates the entire arrangement shown being positioned onto arotary apparatus in a manner similar to the explanation previouslyreferred to with reference to FIG. 13. The assembly is process in amanner as set forth in FIGS. 14 to 19. Thereafter the bell mandrel isremoved to from the formed socket 80.

FIG. 31 is an assembled view of a first pole section 101 of FIGS. 3 to15 inserted into the socket 80 of a second pole section 102 of FIGS. 23to 30. The integral socket enables the first pole section 101 to beinserted into the socket 80 of the second pole section 102 without theneed for ferrules. The integral socket provides an increased strengthand reduced the cost of the carbon fiber tubular pole.

FIG. 32 is a sectional view along line 32-32 in FIG. 31 illustrating anend unit 110 of the first pole sections 101. The second pole section 102is fitted with a similar end unit 111. The end unit 110 comprises awasher stop 112 disposed in a recess 114 formed in the end of the firstpole sections 101. An elastic cord 120 is stretched between the end unit110 of the first pole sections 101 and a similar end unit 111. Theelastic cord 120 maintains the first pole sections 101 inserted withinthe socket 80 of the second pole section 102. The end units 110 and 11also include a canvas snap 122 (lift-a-dot) for mounting a canvas awningor the like.

FIG. 33 is a view of the first and second pole sections of FIG. 30 in afolded position. The first pole section 101 is removed from the secondpole section 102 and may be bent 180 degrees for easy storage.

The present disclosure includes that contained in the appended claims aswell as that of the foregoing description. Although this invention hasbeen described in its preferred form with a certain degree ofparticularity, it is understood that the present disclosure of thepreferred form has been made only by way of example and that numerouschanges in the details of construction and the combination andarrangement of parts may be resorted to without departing from thespirit and scope of the invention.

We claim:
 1. A carbon fiber coupling for coupling tubular poles,comprising: a carbon fiber tubular pole having a narrow cylindricalportion and an enlarged cylindrical portion with an intermediate taperedportion located therebetween; said carbon fiber tubular pole beingformed from a tubular carbon fiber sleeve and a second sleeve disposedto tightly conform against said tubular carbon fiber sleeve; a resinbonding said tubular carbon fiber sleeve to said second sleeve forproviding a unitary carbon fiber tubular pole; an integral socket formedby said enlarged cylindrical portion of said carbon fiber tubular polefor providing a coupling for receiving a narrow cylindrical portion of asecond carbon fiber tubular pole; and said second sleeve being afiberglass sleeve.
 2. A carbon fiber coupling for coupling tubularpoles, comprising: a carbon fiber tubular pole having a narrowcylindrical portion and an enlarged cylindrical portion with anintermediate tapered portion located therebetween; said carbon fibertubular pole being formed from a tubular carbon fiber sleeve and asecond fiberglass sleeve disposed to tightly conform against saidtubular carbon fiber sleeve; a resin bonding said tubular carbon fibersleeve to said second sleeve for providing a unitary carbon fibertubular pole; an integral socket formed by said enlarged cylindricalportion of said carbon fiber tubular pole for providing a coupling forreceiving a narrow cylindrical portion of second carbon fiber tubularpole; and said narrow cylindrical portion of said carbon fiber tubularpole being curved for providing a curved carbon fiber tubular poleconnector.